Title: Introduction on Scale Up Fine Chemicals : From Lab to Plant Site
1Introduction on Scale UpFine Chemicals From
Lab to Plant Site
- By
- Wiratni, PhD
- Gadjah Mada University
- Yogyakarta - Indonesia
2Evolution of chemical engineering
Global trend in chemical industries
Mass production
Specialties/fine chemicals
Focused on CONVERSION
Emphasized on PROPERTIES
Conventional Chemical Engineering
New view in chemical engineering Product
Engineering
3Chemical industries in developing countries
OPERATIONS
PROCESS ENGINEERS
DESIGNERS
LICENCES
NET PROFIT
4Flexibility for changes
International chemical giants (DuPont, BASF, Dow)
Chemical plants in developing countries
Natural resources
Commoditization
STRONG R D
LICENSE!
Specialties
5Price scale
Product engineering
Fine chemicals
Chemical engineering
Crude products
Raw materials
6Position of Biotechnology
- Highly specific in producing particular compounds
? important role in fine chemical production - Characteristics
- - higher level of uncertainty
- - decreasing performance of microorganisms
7Bioprocess Engineering
Raw material (substrate)
Microorganism/enzyme
PURIFICATION UNITS
BIOREACTOR
WASTE
Fermentation Broth
DOWNSTREAM PROCESSING
Product
8Downstream processing
- Very costly can take up to 70 of total
investment - Very important in bioprocess as it determines the
specification of product (purity,
physical/chemical characteristics, etc.)
9Example of Bioproduct
- Poly-?-Hydroxy-Butirate (PHB)
- Biodegradable polymer with high biocompatibility
for medical purposes - Produced intracellularly by microorganisms (e.g.
Alcaligenes euthrophus), using sugar compounds as
substrate
10Nature of PHB
- Characteristics
- Amount of PHB accumulated
- Degree of crystallinity
- Physical/mechanical properties
- Purity
- VERY SENSITIVE TO PROCESS CONDITIONS
11Problems
- PHB is carbon storage for the microorganisms
they will accumulate it when they have plenty of
food, and will consume it when they are lack of
food - Must determine
- When is the optimum harvesting time??
12Problems
- PHB is biodegradable, and so it is susceptible to
oxidation, chlorination, etc. that may lead to
decreasing molecular weight. - Must determine
- What chemicals to be used in purification
process? - What temperature does not destructive to PHB?
13Problems
- If the previous questions have been answered
through laboratory experiments, you may define
optimum conditions (composition of substrate,
temperature, pH, etc) for PHB production. - Bigger problem
- Do those optimum conditions for Erlenmeyer flask
still hold for 100 L fermentor?
14Menghitung kebutuhan power
Power number
Reynold number
15Example Making homogeneous solutions
LAB SCALE
COMMERCIAL SCALE
(IDEAL)
(NON-IDEAL)
16Why studying scale-up techniques?
17Producing Fine Chemicals
- The technology is not matured yet
- Very specific for each particular product
- Very costly if buy licensed technology for each
product - Companies must have very strong RD with two fold
tasks - 1. developing new products
- 2. designing commercial units (SCALE-UP)
18Scale Up in Essential Oil Production
Laboratory experiment
Pilot scale
Commercial scale
SCALE UP PROCESS
19Route to Commercialization
LABORATORY SCALE
TRIAL AND ERROR
MATHEMATICAL MODELS
VERIFICATION IN PILOT PLANT
ERRORS
COMMERCIAL PRODUCTION